Lean manufacturing is a method to make the product flow through your value-added processes without interruption. With the customer's value in focus, lean principles can be applied to the value stream so that optimal product flow is achieved through a pull system starting from the customer.
Panasonic's consulting team will apply lean principles: elimination of waste (muda), overproduction avoidance, value stream mapping, workload leveling (heijunka), continuous improvement processes (kaizen), etc to help you achieve a lean manufacturing environment.
Panasonic Consulting will create synergies of our combined expertise to thoroughly understand the situation and implement the right lean initiatives to help you identify and eliminate waste and streamline your operation.
Successful lean implementations benefits:
- Improved inventory turns
- Improved cash conversion cycles
- Improved ROA
- Improved asset utilization
- Fast market response
Lean Operation Consulting
Lean Operations streamline information and material flow for efficient production with minimized waste. Panasonic's Enterprise Consulting team can help determine if initiatives are needed in your facility to improveWIP reduction, plant layout, labor resource, production control, and material management.
- WIP (Work-in-Process) Reduction
- Decreasing inventory levels and associated costs
- Maintaining a better just-in-time (JIT) system
- Optimizing the use of floor space
- Increasing flexibility to respond to customer needs
- Freeing up cash flow for capital growth
- Plant Layout/Floor Space Analysis
- Establish efficient staging areas for pre-assembly
- Reduce changeover times
- Redesign line layouts to expedite production
- Labor Resource Analysis
- Machine operations
- Feeder setup
- Part exhaust/tape splicing
- Quality control
- Part kitting
- Part kitting
- Material movement operations
- Product changeovers
- Packaging/final assembly
- Production Control Initiatives
- Accelerating responses to unscheduled downtime
- Increasing flexibility to handle manufacturing and scheduling changes
- Creating valuable data to track performance and quality
- Material Management
- Reduce physical inventory counts
- Increase overall inventory accuracy
- Find new opportunities to increase inventory turnovers
- Minimize inventory-related labor costs
- Increase production uptime
WIP can be a major source of manufacturing waste; the challenge is to know where and how WIP is draining your plant's profits and productivity. Panasonic can help you discover and reduce WIP. First we'll analyze manufacturing tasks/processes, inventory management, and other operational areas/practices. We can then assist in implementing proven techniques to create more effective production controls, develop one-piece flow processes, and break the cycle of excess WIP.
Reducing WIP can transform efficiency and profitability by:
Looking for extra space to install a new production line? Need to reorganize your process flow? Even the most compact, crowded plant floor can be hiding valuable opportunities to streamline and simplify your operations. Panasonic can give you a new perspective on your facility and help eliminate bottlenecks and find the space you need to make the most of time and labor resources.
Labor is a vital asset, but the rights skills must be deployed in the right places to minimize redundancies and keep overhead under control. Panasonic can assess your current labor allocation to help you know where and how to avoid excess non-value operations on the plant floor, streamline machine operation tasks, justify necessary overhead needs, and develop new or revised labor allocation plans.
Panasonic can provide unbiased identification of potential operational redundancies in:
With multiple operations running simultaneously within your facility, inefficient communication can have a big impact on production efficiency-creating unnecessary delays and slowing response to unexpected change. Panasonic's consulting team can help with tools and systems designed to make operational status visible from every corner of your facility including: production control boards, efficiency and quality metric initiatives, signal flags, counters, and procedural techniques for managing daily activities.
Better scheduling and production tracking techniques multiply your efficiency by:
While well-managed inventory is critical to your business, physical counts are often inaccurate and short on insight necessary to improve turnover, reduce excess/obsolete stock, and transfer materials efficiently. Panasonic can help find new ways to increase inventory accuracy while reducing inventory management time and costs. Our objective assessments will go over several factors including overall plant inventory management practices, any current inventory software/hardware, and key types/locations of material inaccuracies.
With the right systems and procedures in place to store and track materials, you can:
Lean Asset Configuration
Lean asset configuration assures that your assets are properly allocated and arranged for flexible, efficient production to suit changing demand as well as your short- and long-term needs. Panasonic's Enterprise Consulting team's three-fold approach includes asset allocation initiatives, line utilization analysis, and line layout/floor space analysis.
- Asset Allocation Initiatives
- Minimize capital expenditure
- Ensure on-time delivery capabilities
- Manage risk
- Line Utilization Analysis
- Equipment allocation
- Cycle time balancing
- Parts exhaust and material handling
- Reduction in changeover and unscheduled downtime
- Preventative maintenance practices
- Line Layout/Floor Space Analysis
Panasonic can assist in proactively planning the use of your assets to ensure the right technologies are in place by balancing capacity and resources across one or multiple facilities, identifying gaps, and establishing commonality. This helps meet global demand changes more cost efficiently while strengthening profitability across your enterprise.
Do you have a machine that doesn't run as often as others on the line? Idle equipment can be a drain on line balance and efficiency. Panasonic can analyze your manufacturing lines, identifying underutilized equipment and pinpointing key areas for utilization improvement. Streamlined line productivity makes it easier to maintain quality standards and maximize revenue.
Line utilization analysis helps address:
Floor space utilization is a central part of plant productivity. Making the most of the footprint available can be complicated when an existing layout has evolved without periodic upgrades to maximize efficiency and flow. The Panasonic Enterprise Consulting team can provide a complete footprint analysis and recommend new layouts and systems to achieve ideal line layout.
We know your time is valuable and you can't afford to spend it putting out fires caused by inconsistent quality. That's why Panasonic has a toolbox of solutions designed to elevate and sustain both process and product quality.
Proven techniques include: Six Sigma initiatives, Lean principles, process analysis, materials analysis, scrap/rework reduction initiatives, and material handling assistance (KANBAN, JIT).
From Six Sigma efficiency to minimized customer service costs, quality initiatives enrich your operations at multiple levels by:
- Streamlining material handling/placement
- Reducing scrap/rework expenses
- Improving First Pass Yields (FPY)
- Increasing cash flow through reduced inventory
- Minimizing unscheduled downtime/machine repair costs
Kaizen, the process of implementing lean practices for continuous improvement, aims to better quality and save time and costs across your facility. Panasonic's Enterprise Consulting Group offers the services and expertise of a global manufacturing leader to assist in or perform your company's Kaizen events.
Our Lean- and Six Sigma-certified professionals can address challenges in several areas of the manufacturing process such as: SMT, Pre-SMT assembly operations, NPI, Warehouse, Training, Quality & Inspection, Material Management, Programming, Engineering, SOPs / Documentation, Shipping / Receiving, Final Assembly / Back end processes, and Maintenance.
Together, we can assemble a plan for:
- Streamlining Continuous Flow Processes
- Developing a Pull Production Environment
- Advanced OJT & Specialized Training
- Value Stream Mapping
- Workplace Organization: 5S
- TPM (Total Productive Maintenance)
- Set-up Reduction Click on the pdf for more information .